11.06.2025 by Viktor Siebert
Repair of a Yaskawa CACR-IR3030CB Servopack – A Look Inside
The Case
A long-standing industrial customer sent us a Yaskawa Servopack CACR-IR3030CB for inspection. The unit was part of an older CNC system and had worked reliably for years – until it began showing irregular axis movements and occasional servo alarms. Given the unit’s age and design, we suspected thermal aging, contact issues, or component failures.
Internal Structure and Components
This Servopack is a powerful 2-axis module from the IR series (NC version), rated for up to 3.0 kW per axis and a total system capacity of approx. 6.0 kVA. During incoming inspection, we identified the following internal circuit boards:
| Component | Board Marking | Qty |
|---|
| Control Board | CACR-IR1WC or DF920366-D0 | 1 |
| Power Supply Unit | PE3-2435D | 1 |
| Power Circuit Board | CACR-F2TW1B or DF9200395-C0 | 1 |
| Power Board | 175 or DF9200374-C0 | 1 |
| Output Section | 3030CB | 1 |
Failure Analysis
Our inspection revealed:
- Burned solder joints near the rectifier area on the power board.
- Aged electrolytic capacitors — common cause of voltage drops and ripple noise.
- One pin on the CN21 connector showed corrosion, leading to unstable feedback values.
- Thermal-related faults could be reproduced using hot air and cold spray tests.
Repair Process
The repair included:
- Electrical testing of all power semiconductors (IGBTs, diodes).
- Proactive replacement of all electrolytic capacitors on control and power boards.
- Cleaning and re-soldering of corroded connector pins.
- Oscilloscope analysis of gate signal integrity.
- Full load testing on our test bench with a compatible servo motor and load axis.
Common Issues in CACR-IR Series
- Regenerative fault: Transistor T1 remains closed → Alarm RG (see manual, p. 42)
- Voltage drop due to bad power supply caps → Alarm UV (p. 44)
- Overcurrent: Shunt resistor damage or abnormal motor current → Alarm OC (p. 40)
Technical Highlights (Extract)
- Input voltage: 3~ AC 200–230 V ±10 %, 50/60 Hz
- Control Method: 3-phase rectification, PWM at 46.875 kHz
- Control Signal: Serial RS422
- Weight: approx. 12.9 kg
- Regenerative braking: Built-in
- Protection functions: Overcurrent, Undervoltage, Ground fault, CPU error, etc.
The Result
After the repair, the Servopack ran flawlessly and passed all endurance tests. Interestingly, the customer noted improved positioning accuracy after reinstallation — a clear sign that the feedback loop is now operating with restored precision.
Maintenance Tip
While the CACR-IR series is mechanically solid, issues such as voltage fluctuations, thermal aging, and capacitor degradation pose real risks. If your drive is over 10 years old, preventive maintenance or full refurbishment is strongly advised.
To mentioned Mitsubishi Drive: Yaskawa Servopack CACR-IR3030CB
More details about our Yaskawa repair services can be found here:
Yaskawa drive Repair by Industrypart
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